Operating a Power Tool for a Desired Runtime

This application claims priority to U.S. Provisional Patent Application No. 63/718,359, filed Nov. 8, 2024, the entire content of which is incorporated herein by reference.

The present disclosure relates to battery packs and specifically to adapting power of a battery pack for powering power tools.

Air moving power tools, e.g., vacuums, blowers, and fans, include settings to control the power at which the motors run. For example, a blower may include a high-power setting which runs for a short time period compared to a long time period for a low-power setting. While this gives a user some control on extending runtimes, the short time period and long time period are arbitrary and do not guarantee the user will meet a runtime target.

As will be described in more detail, aspects of the disclosure herein are directed toward a control system for a power tool that allows a user to select a desired runtime for the power tool. The controller enables automatic adjustment to internal operating parameters for the air moving power tool in order to achieve the desired runtime. The adjustments are based on a state of charge and state of health for the battery along with other power tool parameters.

Before any aspects of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in application to the details of the configuration and arrangement of components set forth in the following description or illustrated in the accompanying drawings. Aspects of the disclosure are capable of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof are meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings.

In addition, it should be understood that embodiments may include hardware, software, and electronic components or modules that, for purposes of discussion, may be illustrated and described as if the majority of the components were implemented solely in hardware. However, one of ordinary skill in the art, and based on a reading of this detailed description, would recognize that, in at least one embodiment, the electronic-based aspects may be implemented in software (e.g., stored on non-transitory computer-readable medium) executable by one or more processing units, such as a microprocessor and/or application specific integrated circuits (“ASICs”). As such, it should be noted that a plurality of hardware and software-based devices, as well as a plurality of different structural components, may be utilized to implement the embodiments. For example, “servers,” “computing devices,” “controllers,” “processors,” etc., described in the specification can include one or more processing units, one or more computer-readable medium modules, one or more input/output interfaces, and various connections (e.g., a system bus) connecting the components.

Relative terminology, such as, for example, “about,” “approximately,” “substantially,” etc., used in connection with a quantity or condition would be understood by those of ordinary skill to be inclusive of the stated value and has the meaning dictated by the context (e.g., the term includes at least the degree of error associated with the measurement accuracy, tolerances [e.g., manufacturing, assembly, use, etc.] associated with the particular value, etc.). Such terminology should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the expression “from about 2 to about 4” also discloses the range “from 2 to 4”. The relative terminology may refer to plus or minus a percentage (e.g., 1%, 5%, 10%, or more) of an indicated value.

It should be understood that although certain drawings illustrate hardware and software located within particular devices, these depictions are for illustrative purposes only. Functionality described herein as being performed by one component may be performed by multiple components in a distributed manner. Likewise, functionality performed by multiple components may be consolidated and performed by a single component. In some embodiments, the illustrated components may be combined or divided into separate software, firmware and/or hardware. For example, instead of being located within and performed by a single electronic processor, logic and processing may be distributed among multiple electronic processors. Regardless of how they are combined or divided, hardware and software components may be located on the same computing device or may be distributed among different computing devices connected by one or more networks or other suitable communication links. Similarly, a component described as performing particular functionality may also perform additional functionality not described herein. For example, a device or structure that is “configured” in a certain way is configured in at least that way but may also be configured in ways that are not explicitly listed.

Power tool battery packs are used at worksites to operate various power tools. Setting a predetermined runtime for a power tool enables a user to finish a job without having to change the battery pack.

The present disclosure relates to, in one aspect, a battery pack for powering an air moving tool, the air moving tool comprising a motor and a controller for controlling an amount of power provided to the motor from the battery pack over the course of a predetermined time.

In some aspects, the techniques described herein relate to a method of operating a power tool for a desired runtime, the method including: determining, with a controller for the power tool, at least one parameter of a battery pack connected to the power tool; generating, with the controller, an available capacity in ampere-hours based on the at least one parameter; receiving, at the controller, a runtime mode associated with a desired runtime; calculating, with the controller, a required current draw based on the available capacity and the runtime mode to achieve the desired runtime; drawing an amount of current equal to the calculated required current draw to operate the power tool; determining that the power tool has operated for the desired runtime; and ceasing operation of the power tool in response to determining that the power tool has operated for the desired runtime.

In some aspects, the techniques described herein relate to a method, further including collecting, with a set of sensors in communication with the controller, a set of variables, including a voltage and a current of the battery pack.

In some aspects, the techniques described herein relate to a method, further including determining, with the set of sensors, a battery temperature of the battery pack.

In some aspects, the techniques described herein relate to a method, further including predicting, with a pack thermal model (PTM) of the controller, a battery temperature of the battery pack.

In some aspects, the techniques described herein relate to a method, wherein determining the at least one parameter of the battery pack further includes calculating, at the controller, a state of charge (SoC) of the battery pack using a machine learning algorithm.

In some aspects, the techniques described herein relate to a method, further including determining a pack ID of the battery pack based on the determined at least one parameter using a machine learning algorithm.

In some aspects, the techniques described herein relate to a method, further including receiving, at the controller, one or more updated parameters of the battery pack and recalculating, with the controller, the current draw required to achieve the desired runtime based on the updated parameters of the battery pack.

In some aspects, the techniques described herein relate to a method, further including updating operation of the power tool to operate at the recalculated current draw.

In some aspects, the techniques described herein relate to a method, wherein estimating the at least one parameter includes at least one selected from a list consisting of: a state of charge (SoC), a state of health (SoH), or a battery impedance (DCIR).

In some aspects, the techniques described herein relate to a method, wherein the at least one parameter is provided by a battery pack controller of the battery pack.

In some aspects, the techniques described herein relate to a method, further including operating a motor to draw the amount of current equal to the calculated required current drawn to operate the power tool.

In some aspects, the techniques described herein relate to a power tool, including: a set of sensors configured to measure a set of variables associated with a battery pack coupled to the power tool, wherein the set of variables includes a current or a voltage of the battery pack; a human machine interface configured to generate a runtime mode output, wherein the runtime mode output indicates a desired runtime of the power tool; and a controller configured to determine at least one operating parameter for the battery pack based on the set of variables and adapt an amount of current drawn from the battery pack based on the desired runtime and the at least one operating parameter.

In some aspects, the techniques described herein relate to a power tool, further including a motor.

In some aspects, the techniques described herein relate to a power tool, wherein the set of variables further includes a battery temperature of the battery pack.

In some aspects, the techniques described herein relate to a power tool, wherein the controller includes a pack thermal model (PTM) configured to determine a battery temperature of the battery pack based on a mathematical model.

In some aspects, the techniques described herein relate to a power tool, wherein the at least one operating parameter includes at least one selected from a list consisting of: a state of charge (SoC), a state of health (SoH), or a battery impedance (DCIR).

In some aspects, the techniques described herein relate to a power tool, the controller is configured to determine a pack ID of the battery pack.

In some aspects, the techniques described herein relate to a power tool including: a battery pack interface for engaging with a battery pack to power the power tool; a set of sensors for measuring a set of variables associated with the battery pack; and a controller, the controller configured to: determine a state of charge of the battery pack based on the set of variables; generate an available capacity in ampere-hours based on the state of charge; receive a selected runtime mode associated with a desired runtime mode indicating a desired runtime; calculate a required current draw in amperes based on the available capacity and the selected runtime mode; and operate the power tool to draw an amount of current equal to the required current draw to achieve the desired runtime.

In some aspects, the techniques described herein relate to a power tool, wherein the controller is configured to determine a state of health (SoH) or a battery impedance (DCIR) associated with the battery pack and based on the set of variables.

In some aspects, the techniques described herein relate to a power tool, wherein the controller includes a pack thermal model (PTM) configured to determine a battery temperature of the battery pack based on a mathematical model.

Other independent aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings.

1 FIG. 3 FIG. 100 110 110 110 324 110 100 110 110 100 100 110 110 110 100 100 110 100 110 i i i i is a schematic illustrating a battery packand a power tool. The power toolmay be an air moving power tool, e.g., a blower, fan, or vacuum. The power toolmay include a motor() for providing power to the power toolwhen the battery packis engaged with the power tool. In other implementations the power toolis non-motorized, e.g., a work light, site light, or search light. The battery packincludes a battery interfacefor engagement with the power tool. The power toolincludes a corresponding power tool interfacefor engagement with the battery pack. The interfaces,may be any suitable interfaces for electrically connecting the battery packto the power tool, including, for example corresponding sliding interfaces or a pocket interface with a corresponding insertable interface.

Other types of power tools contemplated include, by way of example, motorized power tools (e.g., a cut-off saw, a miter saw, a table saw, a core drill, an auger, a breaker, a demolition hammer, a compactor, a vibrator, a compressor, a drain cleaner, a welder, a cable tugger, a pump, etc.), outdoor tools (e.g., a chain saw, a string trimmer, a hedge trimmer, a blower, a lawn mower, etc.), other motorized devices (e.g., vehicles, utility carts, a material handling cart, etc.), and non-motorized electrical devices (e.g., a power supply, a light, an AC/DC adapter, a generator, etc.).

100 110 100 114 100 110 116 100 When engaged with each other, the battery packand the power toolcan exchange information related to operating parameters of the battery pack. Operating parametersmay include, but are not limited to, a state of charge (“SoC”), a state of health (“SoH”), a battery impedance or a direct current internal resistance (“DCIR”), and/or other operating parameters as required for a given application. The battery packand power toolcan also exchange information regarding a set of variablesassociated with internal measurements of the battery pack, including but not limited, a battery current (“I”), a battery voltage (“V”), a battery temperature (“T”), and/or other battery measurements as required for a given application.

2 FIG. 1 FIG. 3 FIG. 210 110 210 212 214 312 216 212 218 218 216 212 214 218 218 a b a b illustrates a vacuum assemblyaccording to one example of the power toolfrom. The vacuum assemblyis a form of a wet/dry vacuum assembly including a collection vessel or containerhaving a bodydefining a collection volume() therein. A power headmay be removably couplable to the collection containervia a first coupling elementconfigured to form a releasable connection with a corresponding second coupling elementof either the power heador an intermediate stack accessory. More specifically, the containerincludes a lip formed into the bodythereof to which a latch may releasably engage. While the illustrated coupling elements,are a lip and a corresponding latch to be used together, it is understood that in other implementations the positions may be reversed. In still other implementations, other forms of connection (e.g., latches, clamps, clips, and the like) may be used.

216 220 318 222 220 220 222 222 222 222 224 220 312 210 216 212 222 226 224 222 230 232 232 210 3 FIG. 3 FIG. 3 FIG. f t b s f f The power headincludes a head housingat least partially enclosing a power head volume() therein. A series of walls or platesat least partially define the head housing. More specifically, the head housingincludes a face plate or front wall, a top plate, a back plate(), and a pair of side walls. An inlet passagemay extend between and be open to an exterior of the head housingand the collection volume() of the vacuum assemblywhen the power headis attached to the container. The front wallmay include an inletopen to the inlet passage. Additionally, the front wallmay include one or more battery terminalsand a user interface panel. The user interface panelgenerally includes one or more user inputs (i.e., buttons, displays, touch screens, and the like) to operate the vacuum assembly.

222 216 234 234 236 222 236 222 238 210 240 242 240 210 238 242 244 238 242 t t t The top plateof the power headmay be formed to include a docking interfaceconfigured to allow one or more accessories (e.g., storage containers, tools, bags, pouches, organizers, and the like) to be releasably attached thereto. More specifically, the illustrated docking interfaceincludes a plurality of individual connection elements or points, each formed into or otherwise attached to the top plate. The connection pointsare each able to form a releasable connection with a corresponding accessory. In the illustrated implementation, the top plateis substantially planar and defines a top plane. The vacuum assemblyincludes a support surfacedefining a support planethat is parallel to the support surface uponupon which the vacuum assemblyrests during operation. In the illustrated implementation, the top planeis parallel to the support plane. A stack axisextends normal to the top planeand the support plane.

3 FIG. 2 FIG. 210 300 214 212 310 218 310 312 214 314 310 314 312 300 312 310 218 310 242 is a schematic cross-sectional view of the vacuum assemblyfromillustrating a blower assemblydisposed therein. The bodyof the containerincludes a base walland the plurality of side wallsthat extend from a periphery of the base wallto define the collection volume. The bodyis open at an open endopposite of the base wall. The open endprovides access to the collection volume. At least a portion of the blower assemblyextends into the collection volume. The base wallmay be generally octagonal in shape where eight side wallsextend upwardly therefrom. However, in other implementations, different shaped containers may be present. In the illustrated implementation, the base wallis parallel to the support plane.

314 212 316 216 316 a a The open endof the containermay include a first connection interfaceto which other devices may be releasably attached (e.g., the power heador other intermediate stack accessories). During use, the first connection interfaceserves to physically align the connected elements (e.g., vertically, horizontally, and rotationally) while also establishing an internal connection region. The internal connection region, in turn, serves as an area where various operable connections (e.g., airflow passage connections, electrical connections, debris passage connections, and the like) may be made and the transfer of material (e.g., air, dust, debris, and the like) may occur within the confines of the assembled vacuum's structure.

300 318 220 318 320 322 322 242 216 212 222 320 222 b f. The blower assemblyis at least partially positioned within the power head volumeof the head housing. The power head volumeis at least partially defined by a bottom or base walldefining a base wall planegenerally parallel thereto. The base wall planeis parallel to the support planewhen the power headis attached to the container. The back plate, or back wall, extending from the base wallopposite the front wall

320 216 316 212 316 316 b b The base wallof the power headmay include a second connection interfaceto which other devices may be releasably attached (e.g., the containeror other intermediate stack accessories). During use, the second connection interfaceserves to physically align the connected elements (e.g., vertically, horizontally, and rotationally) while also establishing an internal connection region. The internal connection region, in turn, serves as an area where various operable connections (e.g., airflow passage connections, electrical connections, debris passage connections, and the like) may be made and the transfer of material (e.g., air, dust, debris, and the like) may occur within the confines of the assembled vacuum's structure.

300 324 326 328 226 324 328 326 210 100 324 324 The blower assemblymay include a motor, a volute, and an impellerpositioned within the voluteand rotatable with respect thereto. During use, electrical power is provided to the motorwhich, in turn, rotates the impellerrelative to the volutegenerating airflow within the vacuum assembly. A primary power source (e.g., a battery pack) provides electrical power to energize the motor. The motoris energized based on a selection of the power button and, optionally, one or modes or settings selected by the user or automatically determined by the controller as described in further detail below.

330 244 330 100 420 210 100 420 256 In the illustrated implementation, a battery introduction axisis oriented such that it forms a first angle θ relative to the stack axis. More specifically, the battery introduction axisis oriented (i.e., the first angle θ is sized) so that it is sufficiently angled to allow the user to readily read the battery level indicator on the battery packwhen installed on the terminal, but also sufficiently vertical so that the vacuum assemblydoes not roll or otherwise move due to the docking force F applied to the battery packwhen being installed in the terminal. More specifically, in some implementations the first angle θ is approximately 5 degrees, 10 degrees, 15 degrees, and 20 degrees (+1%, +2%, +5%, +10%). In still other implementations, the first angleis between 1 degree and 10 degrees, between 2 degrees and 10 degrees, between 5 degrees and 10 degrees, between 5 degrees and 15 degrees, between 5 degrees and 20 degrees, between 1 degree and 15 degrees, between 5 degrees and 15 degrees, and between 5 degrees and 20 degrees.

210 332 226 224 332 226 334 332 332 332 The vacuum assemblymay also include a vacuum hosethat may be releasably coupled to the inletof the inlet passage. Specifically, the vacuum hoseis an elongated element having a first end θ removably couplable to the inletand a second or distal endopposite the first end θ. In some implementations, all or a portion of the hosemay be flexible. In other implementations, all or a portion of the hosemay be rigid. In still other implementations, the hosemay be formed as a single piece or include a plurality of individual sub-segments that can be combined in various combinations to produce the desired hose configuration.

4 FIG.A 400 210 400 410 412 414 416 418 232 420 420 410 100 420 100 414 414 420 412 410 illustrates control systemfor the vacuum assemblyaccording to one example. The control systemincludes a controller, a wireless communication controller, a power input unit, a switching network, sensors, the user interface panel, and a set of battery terminals. The set of battery terminalsare coupled to the controllerand couples to the battery pack. The set of battery terminalstransmit power received from the battery packto the power input unit. The power input unitincludes active and/or passive components (e.g., voltage step-down controllers, voltage converters, rectifiers, filters, etc.) to regulate or control the power received through the set of battery terminalsand to the wireless communication controllerand the controller.

416 410 324 210 420 324 416 The switching networkenables the controllerto control the operation of the motor. Generally, when the vacuum assemblyis turned on, electrical current is supplied from the set of battery terminalsto the motor, via the switching network.

410 232 422 410 416 324 416 324 324 416 416 410 324 416 210 324 232 422 416 380 210 210 In response to the controllerreceiving a power on signal from the user interface panelor a remote, the controlleractivates the switching networkto provide power to the motor. In some implementations, the switching networkcontrols the amount of current available to the motorand thereby controls the speed and torque output of the motor. The switching networkmay include numerous field-effect transistors (“FETs”), bipolar transistors, or other types of electrical switches. For instance, the switching networkmay include a six-FET bridge that receives pulse-width modulated (“PWM”) signals from the controllerto drive the motor. In some implementations, the switching networkcontrols power consumption of the vacuum assembly(the current and voltage supplied to the motor) based on one or more modes or settings selected by a user via the user interface panel, the remote, or both. In some implementations, the switching networkcontrols the current and voltage supplied to the motorbased on usage of the vacuum assembly(whether or not the vacuum assemblyis idle).

418 410 410 210 418 418 418 418 418 418 418 418 410 324 418 410 210 210 410 416 380 416 420 380 410 100 416 The sensorsare coupled to the controllerand communicate to the controllervarious signals indicative of different parameters of the vacuum assembly. The sensorsinclude one or more Hall effect sensorsA, one or more voltage sensorsB, one or more current sensorsC, one or more infrared (IR) sensorsD, one or more Piezo sensorsE, one or more pressure sensorsF, and/or sensors as required for a given application. Each Hall effect sensorA outputs motor feedback information to the controller, such as an indication (e.g., a pulse) when a magnet of a rotor of the motorrotates across the face of that Hall effect sensor. Based on the motor feedback information from the Hall effect sensorsA, the controllercan determine the position, velocity, and acceleration of the rotor. In response to the motor feedback information and one or more signals, such as a desired mode of the vacuum assembly(for example, whether the vacuum assemblyis in low power mode or high-power mode), the controllertransmits control signals to control the switching networkto drive the motor. For instance, by selectively enabling and disabling the FETs of the switching network, power received via the battery terminalsis selectively applied to stator coils of the motorto cause rotation of its rotor. The current and voltage information is used by the controllerdetermine power being supplied by the battery packand ensure proper timing of control signals to the switching network.

232 422 410 210 232 210 210 210 210 In some implementations, the user interface paneland/or remotereceives control signals from the controllerto convey information based on different states or modes of the vacuum assembly. For example, the user interface panelincludes indicators such as one or more light-emitting diodes (“LEDs”), or a display screen and can be configured to display conditions of, or information associated with, the vacuum assembly. For example, the indicators may be configured to indicate measured electrical characteristics of the vacuum assembly, the status of the vacuum assembly, the mode of the vacuum assembly, etc. In some implementations, this information may be conveyed to a user through audible or tactile outputs.

410 210 410 410 210 410 430 432 434 436 430 430 440 442 444 410 As described above, the controlleris electrically and/or communicatively connected to a variety of modules or components of the vacuum assembly. In some implementations, the controllerincludes a plurality of electrical and electronic components that provide power, operational control, and protection to the components and modules within the controllerand/or vacuum assembly. For example, the controllerincludes, among other things, a processing unit(e.g., a microprocessor, a microcontroller, electronic processor, electronic controller, or another suitable programmable device), a memory, input units, and output units. The processing unit(herein, electronic processor) includes, among other things, a control unit, an arithmetic logic unit (“ALU”), and a plurality of registers. In some implementations, the controlleris implemented partially or entirely on a semiconductor (e.g., a field-programmable gate array [“FPGA”] semiconductor) chip, such as a chip developed through a register transfer level (“RTL”) design process.

432 433 430 432 432 210 432 410 410 410 432 210 418 410 The memoryincludes, for example, a program/data storage area and a machine learning data storage area. The program storage area and the data storage area can include combinations of different types of memory, such as a read-only memory (“ROM”), a random access memory (“RAM”) (e.g., dynamic RAM [“DRAM”], a synchronous DRAM [“SDRAM”], etc.), an electrically erasable programmable read-only memory (“EEPROM”), a flash memory, a hard disk, a secure digital (“SD”) card, or other suitable magnetic, optical, physical, or electronic memory device(s). The electronic processoris connected to the memoryand executes software instructions that are stored in a memory(e.g., RAM during execution), a ROM (e.g., on a generally permanent basis), or another non-transitory computer readable medium such as another memory or a disc). Software included in the implementation of the vacuum assemblycan be stored in the memoryof the controller(e.g., in the program storage area). The software includes, for example, firmware, one or more applications, program data, filters, rules, one or more program modules, and other executable instructions. The controlleris configured to retrieve from memory and execute, among other things, instructions related to the control processes and methods described herein. The controlleris also configured to store vacuum information on the memoryincluding operational data, information identifying the type of vacuum, a unique identifier for the particular vacuum, and other information relevant to operating or maintaining the vacuum assembly. The vacuum usage information, such as current levels, motor speed, motor acceleration, whether the vacuum is actively vacuuming, may be captured or inferred from data output by the sensor(s). Such information may then be accessed with the external electronic device. In other constructions, the controllerincludes additional, fewer, or different components.

432 210 210 210 The memorystores various identifying information of the vacuum assemblyincluding a unique binary identifier (UBID), an American Standard Code for Information Interchange [“ASCII”] serial number, an ASCII nickname, and a decimal catalog number. The UBID both uniquely identifies the type of vacuum and provides a unique serial number for each vacuum assembly. Additional or alternative techniques for uniquely identifying the vacuum assemblyare used in some implementations.

4 FIG.B 412 412 454 456 458 454 422 458 456 458 210 422 458 450 210 470 458 450 410 illustrates a schematic of the wireless communication controlleraccording to one example. The wireless communication controllerincludes a radio transceiver and an antenna, a memory, and an electronic processor. The radio transceiver and antennaoperate together to send and receive wireless messages to and from the remoteand the electronic processor. The memorycan store instructions to be implemented by the electronic processorand/or may store data related to communications between the vacuum assemblyand the remoteor the like. The electronic processorfor the wireless communication controllercontrols wireless communications between the vacuum assemblyand the remote. For example, the electronic processorassociated with the wireless communication controllerbuffers incoming and/or outgoing data, communicates with the controller, and determines the communication protocol and/or settings to use in wireless communications.

450 470 470 210 450 450 In the illustrated implementation, the wireless communication controlleris a Bluetooth® controller. The Bluetooth® controller communicates with the remoteemploying the Bluetooth® protocol. Therefore, in the illustrated implementation, the remoteand the vacuum assemblyare within a communication range (i.e., in proximity) of each other while they exchange data. In other implementations, the wireless communication controllercommunicates using other protocols (e.g., Wi-Fi®, cellular protocols, a proprietary protocol, etc.) over a different type of wireless network. For example, the wireless communication controllermay be configured to communicate via Wi-Fi® through a WAN, such as the Internet or a LAN, or to communicate through a piconet (e.g., using infrared or near-field communications (“NFC”).

412 410 422 454 412 422 454 410 The wireless communication controlleris configured to receive data from the controllerand relay the information to the remotevia the transceiver and antenna. In a similar manner, the wireless communication controlleris configured to receive information from the remotevia the transceiver and antennaand relay the information to the controller.

5 FIG. 1 2 3 FIGS.,, and 500 100 110 100 512 512 514 516 518 100 512 114 100 is a schematic illustrating a control systemfor the battery packand the power toolillustrated inaccording to one example. The battery packincludes a battery controller(e.g., part of a Battery Management System “BMS”). The battery controllerincludes a battery memoryfor storing, by way of example a battery pack IDand charge/discharge statisticsassociated with the battery pack. The battery controlleris configured to estimate at least one operating parameterof the battery back.

516 100 516 516 518 The battery pack IDmay be defined by a nominal voltage, a current capacity, a connection configuration (e.g., “tower” vs. “slide-on”), etc., of the battery pack. For example, the battery pack IDmay identify a high-power battery pack with a nominal voltage of about 12V and having a tower-style configuration. In another example, the battery pack IDmay identify a high-power battery pack with a nominal voltage of 18V and a slide-on configuration. The charge/discharge statisticsmay include information regarding life span of the battery, previous charging information, compatible power tools, or the like.

110 410 526 528 432 526 110 114 100 528 100 430 114 516 100 The power toolincludes a tool controller, by way of example the controllerdescribed herein. A Machine learning (“ML”) moduleand a pack thermal model (PTM)may be stored in the memory. The ML modulemay include programming for predicting or calculating information regarding a runtime for the power toolbased on the operating parametersof the battery back. In one aspect the PTMdetermines the temperature of the battery pack. In one aspect, the processoris configured to estimate at least one of the operating parameters(e.g., the SoC) and the pack IDof the battery back.

418 100 114 100 418 418 418 418 100 418 100 418 100 One or more of the sensorsmay be integral with the battery packfor providing measurements associated with the operating parameters. For example, to determine the state of charge (SoC) of the battery packthe voltage sensorB, the current sensorD, and the temperature sensorE may be utilized. In one example, temperature sensorE is a thermistor or a digital temperature sensor integral with the battery packfor measuring the battery temperature T. In one example, the current sensorD is a shunt resistor and an analog to digital converter (ADC) integral with the battery packfor measuring the battery current I. In one example, the voltage sensorsB is a voltage divider combined with the ADC or a battery monitor integrated circuit (IC) integral with the battery packfor measuring the battery voltage V.

418 110 418 100 110 100 Additionally, one or more of the sensorsmay be integral with the power tool. In one example the Hall effect sensorA measures current flow between the battery packand the power tool, and in turn contributes to determining the SoC of the battery pack.

418 114 418 418 418 The sensorsmay be utilized separately or in combination to determine other operating parametersincluding the state of health (SoH) and the battery impedance (DCIR). For example, to determine the SoH and/or the DCIR measurements from the voltage sensorB, the current sensorD, and the temperature sensorE may be utilized.

500 534 110 324 324 534 110 110 534 264 534 422 110 450 536 538 110 536 534 536 110 534 The control systemincludes a Human Machine Interface (“HMI”)for controlling an amount of power provided to the power tool, by way of example to the motorfor controlling a speed of the motor. In other implementations the HMIprovides various current draw amounts in relation to lighting (e.g., to adjust brightness) where the power toolis a site light or LEDs are integrated into the power tool. The HMImay be the user interface paneldescribed above. It is also contemplated that the HMIis a separate wireless HMI, such as on a smart device, (e.g., the remote, a smart phone, tablet computer, and/or other devices as required for a given application), that is in electronic communication with the power tool, such as via the wireless communication controller. In one embodiment, the HMI may be a smart device equipped with One-Key® from Milwaukee Electric Tool®. A set of inputsare used to select different runtime modes, illustrated by way of example as three modes, for the power tool. By way of example, Mode 1 may be associated with a desired runtime of 15 minutes, mode 2 may be associated with a desired runtime of 30 minutes, and mode 3 may be associated with a desired runtime of 1 hour. The set of inputsmay be buttons on the HMIas illustrated. It is also contemplated that the set of inputsmay be integral with the power tooland the HMI.

500 540 110 100 110 100 100 540 100 110 The control systemincludes indicator(s), for example LEDs, that light up to indicate that the power toolis on, that the battery packis engaged with the power tool, that the battery packis charged, or that the battery packis in need of a charge, and the like. As illustrated the indicator(s)may be separate indicator(s) dedicated to the battery packand to the power toolrespectfully.

538 536 430 100 114 538 430 114 100 100 114 110 In one example, after a user selects one of the runtime modesassociated with a desired runtime via the set of inputs, the electronic processorwill calculate an amount of current to be drawn from the battery packto achieve the desired runtime. These calculations are based on the operating parameters(e.g., SoC, SoH, and DCIR) and the selected runtime mode. The electronic processormay use a combination of one or more operating parametersof the battery packto determine how much power is required to meet the selected runtime mode. In other words, an amount of current drawn from the battery packis adapted based on the available operating parametersin order for the power toolto operate for the desired runtime. The calculations may be performed in a variety of ways described in more detail herein.

6 FIG. 600 100 110 418 116 116 212 114 512 100 116 212 516 518 514 212 100 116 518 114 110 is a schematic flow diagramfor control of the battery packand the power toolaccording to an example. The sensorsmeasure and distribute the set of variables(e.g., the battery temperature T, the battery current I, and the battery voltage V). The set of variablesis provided to the battery controllerto determine the operating parameters. The battery controlleris configured to estimate the SoC and the DCIR of the battery backbased on the set of variables. The battery controlleralso receives the pack IDand the charge/discharge statisticsfrom the memory. The battery controlleris configured to estimate the SoH of the battery packbased on the set of variablesand the charge/discharge statistics. The operating parametersare sent to the power toolfor determining the amount of current drawn for meeting the desired runtime.

7 FIG. 7 FIG. 700 110 100 700 212 410 illustrates a flow diagram for a methodof implementing a desired runtime operation for the power toolwith the battery packof. The methodmay be carried out by the battery controllerand/or the controller.

710 212 114 518 430 212 116 116 518 At process block, the battery controllerestimates at least one of the operating parametersbased on the battery current I, the battery voltage V, the battery temperature T, and/or the charge/discharge statistics. In one example, using the processing unit, the battery controllerestimates the SoC and the DCIR based on the set of variablesand the SoH based on the set of variablesand the charge/discharge statisticsand utilizing Equation 1, Equation 2, and Equation 3.

712 100 110 512 410 516 114 114 At process block, upon engagement between the battery packand the power tool, the battery controllersends a signal to the controllerassociated with the pack IDand at least one of the operating parameters. In one example, the signal sent includes all of the operating parameters.

714 410 430 410 516 114 At process block, the controller, via the processing unit, generates an available capacity in ampere-hours (Ah). The controllermay utilize all or one of the received pack IDand the operating parametersto generate the available capacity utilizing Equation 4 or Equation 5.

716 410 536 538 At process block, the controllerreceives, via the set of inputs, the runtime modeassociated with the desired runtime. For example, a user may select mode 2 which is associated with a desired runtime of 30 minutes.

718 410 430 538 At process block, the controller, via the processor, calculates a current draw in amperes (A) based on the available capacity (from Equation 4 or Equation 5) and the requested runtime modeto achieve the desired runtime using Equation 6.

720 410 100 110 410 110 At process block, the controllerinitiates discharge of the battery packusing the calculated current draw to operate the power tool. In some embodiments, the controllercontrols the power toolbased on the calculated current draw to facilitate operating for the desired runtime.

410 722 100 114 512 110 110 410 324 410 324 The controllermay track an amount of runtime based solely on the initial parameter readings as described above. It is further contemplated that at blockthe controller periodically queries the battery packfor updated operating parametersand the battery controllerrecalculates the required current draw to ensure that the power toolwill meet the desired runtime. The power of the power toolmay vary as the current does. For example, in response to determining that the required current draw is less than the initial current draw, the controllermay reduce the output power of the motorto control the current draw. Similarly, in response to determining that the required current draw is greater than the initial current draw, the controllermay increase the output power of the motorto control the current draw.

724 410 100 110 110 At process block, the controllerceases operation of the power tool, thereby stopping the current draw from the battery packto the power tool, to stop operation of the power toolupon reaching the desired runtime.

8 FIG. 800 820 110 820 100 820 110 110 820 820 110 is a schematic flow diagramfor a control of a battery packand the power toolaccording to an aspect of the disclosure herein. The battery packmay be similar to the battery packalready described herein; however, the battery packmay be configured to only provide power (i.e., current and voltage) to the power tool, but no additional data (e.g., SoH, SoC, DCIR, etc.) to the power tool. In this example, it is contemplated that the battery packincludes only the basics required for the battery packto provide power to the power tool.

110 418 418 418 116 528 410 528 820 430 430 516 502 516 410 110 410 526 110 516 410 110 324 824 820 As described previously herein, the power toolincludes the current sensorC and the voltage sensorB of the sensorsfor collecting the set of variablesincluding the battery current (“I”) and the battery voltage (“V”). The pack thermal model (PTM)is configured to determine the battery temperature T. In one embodiment, the controllerin conjunction with the PTMmay determine the temperature based on a mathematical model that predicts the temperature of the battery pack. The sensed battery voltage, sensed battery current, and the determined battery temperature T are then provided to the processor. The processoris configured to estimate the SoC and/or the pack IDof the battery backbased on the sensed battery current I, the sensed battery voltage V, and the determined battery temperature T. Based on the SoC and/or pack ID, the controllermay determine an available runtime of the power tool. In some examples, the controllermay implement machine learning, such as via the ML moduleto predict information regarding a probable runtime for the power toolbased on the SoC and the pack ID. The controllerthen controls the power tool, e.g., the motoror an LED, to draw an amount of current from the battery packrequired to meet the desired runtime, as described above.

526 432 430 410 410 In some implementations, the ML moduleis retrieved from the memoryand executed using the processor. To implement one or more machine learning algorithms, the controlleris configured to learn a general rule or model that maps the inputs to the outputs based on the provided example input-output pairs. The machine learning algorithm may be configured to perform machine learning using various types of methods. For example, the controllermay implement the machine learning program using decision tree learning (such as random decision forests), associates rule learning, artificial neural networks, recurrent artificial neural networks, long short term memory neural networks, inductive logic programming, support vector machines, clustering, Bayesian networks, reinforcement learning, representation learning, similarity and metric learning, sparse dictionary learning, genetic algorithms, k-nearest neighbor (KNN), among others, such as those listed in Table 1 below.

TABLE 1 Recurrent Recurrent Neural Networks [“RNNs”], Long Short-Term Memory Models [“LSTM”] models, Gated Recurrent Unit [“GRU”] models, Markov Processes, Reinforcement learning Non-Recurrent Deep Neural Network [“DNN”], Convolutional Neural Network [“CNN”], Models Support Vector Machines [“SVM”], Anomaly detection (ex: Principle Component Analysis [“PCA”]), logistic regression, decision trees/forests, ensemble methods (combining models), polynomial/Bayesian/other regressions, Stochastic Gradient Descent [“SGD”], Linear Discriminant Analysis [“LDA”], Quadratic Discriminant Analysis [“QDA”], Nearest neighbors classifications/regression, naïve Bayes, attention networks, transformer networks, etc.

410 410 210 210 The controlleris programmed and trained to perform a particular task using the machine learning algorithm. For example, in some implementations, the controlleris trained to determine whether the vacuum assemblyis actively vacuuming or is idle. The training examples used to train the machine learning algorithm may be graphs or tables of sensor data, vacuum mode, and whether the vacuum assemblyis actively vacuuming or idle. The training examples may be previously collected training examples, from, for example, a plurality of the same type of vacuums. For example, the training examples may have been previously collected from a plurality of vacuums of the same type (for example, the same make and model) over a span of, for example, one year.

410 410 210 410 410 A number of different training examples is provided to the controller. The controllermay use these training examples to generate a machine learning algorithm (e.g., a rule, a set of equations, and the like) that helps categorize the vacuum assemblyas actively vacuuming or idle based on new input data. The controllermay weight different training examples differently to, for example, prioritize different conditions or inputs and outputs to and from the controller. For example, certain observed operating characteristics may be weighed more heavily than others.

9 FIG. 900 110 802 900 410 is a flowchart illustrating a processof implementing a desired runtime for the power toolwith the battery pack. The processmay be carried out by the controller.

910 820 110 802 410 At process block, the battery packis engaged with the power tool. The battery pack, as described above, does not transmit any additional data (e.g., SoC, SoH, DCIR, battery ID, etc.) to the controller. Receiving no data from a battery pack upon engagement with a power tool

912 410 802 418 418 At process block, the controllersenses initial measurements of V and I for the battery packvia the current sensorC and the voltage sensorB.

914 410 802 410 528 802 At process block, the controllercalculates the battery temperature T of the battery pack. In one example, the controllermay utilize the PTMto determine the battery temperature T of the battery pack.

916 410 820 410 820 410 820 820 At process block, the controllercalculates the SoC of the battery packbased on at least the sensed battery voltage V, the sensed current I, and the determined battery temperature T. In some embodiments, the controllermay implement one or more machine learning algorithms to determine the SoC of the battery pack. In some embodiments, the controllermay be configured to determine other parameters of the battery pack, such as the DCIR, the SoH, and/or the pack ID of the battery pack, as required for a given application.

918 410 820 820 820 820 410 410 820 At process block, the controllergenerates an estimated available capacity in ampere-hours (Ah) of the battery pack. In one embodiment the estimated available capacity of the battery packis determine based on the SoC of the battery pack. In other examples, additional parameters, such as the pack ID, SoH, and voltage V of the battery packmay be used by the controllermay be used to determine the available capacity. In further examples, the controllermay use one or more machine learning algorithms to determine the available capacity of the battery pack.

920 410 536 110 534 At process block, the controllerreceives, via the set of inputs, a runtime mode input associated with the desired runtime. The runtime mode provides a desired runtime of the power tool. For example, the runtime mode input may be received via the HMI.

922 410 538 At process block, the controllercalculates a required current draw in amperes (A) based on the estimated available capacity and the requested runtime mode. The required current draw may be the maximum current permitted to be drawn to achieve a desired runtime based on the received runtime mode input.

924 410 110 410 416 324 At process block, the controllerinitiates operation of the power toolat a level such that the consumed power is substantially equal to the required current draw associated with the desired runtime. For example, the controllermay control the switching networkto regulate the power provided to the motor.

410 926 In some examples, the controllermay track the runtime based solely on the initial estimated available capacity as described above. It is further contemplated that at blockthe controller periodically updates the estimated available capacity. The updated estimated available capacity may be determined similarly to the estimated available capacity as described above.

928 410 110 At process block, the controllerupdates the motor operation based on the updated estimated available capacity to ensure that the power toolwill meet the desired runtime.

930 410 110 At process block, the controllerdetermines that the desired runtime has been reached and stops operation of the power tool.

Although the disclosure has been described with reference to certain preferred aspects, variations and modifications exist within the scope and spirit of one or more independent aspects of the disclosure as described. Various features and advantages of the disclosure are set forth in the following claims.